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Abstract:

A bearing arrangement in an actuating motor of an electrical camshaft
adjuster, including: a first, bowl-shaped housing part made of metal; a
second housing part made of plastic, closing off the first housing part;
a first roller bearing which is held in the first housing part; a second
roller bearing which is inserted into the second housing part; and a
shaft mounted by means of the first and second roller bearings. The first
roller bearings is designed as a fixed bearing. A contact surface which
transmits force, and which is smaller than the inner running surface of
an inner ring of the first roller bearing, is formed between the shaft
and the inner ring. The first roller bearing is designed as an open
bearing which is lubricated by an operating medium. The second roller
bearing is designed as a sealed bearing with a lifetime supply of grease.

Claims:

1. A bearing arrangement in an actuating motor of an electrical camshaft
adjuster, comprising: a first, bowl-shaped housing part made of metal; a
second housing part made of plastic, closing off the first housing part;
a first roller bearing which is held in a first housing part; a second
roller bearing which is inserted into the second housing part; and, a
shaft mounted by means of the roller bearings, wherein: one of the first
or second roller bearings is designed as a fixed bearing; a contact
surface which transmits force, and which is smaller than the inner
running surface of an inner ring, is formed between the shaft and an
inner ring of the first roller bearing; the first roller bearing is
designed as an open bearing which is lubricated by an operating medium;
and, the second roller bearing is designed as a sealed bearing with a
lifetime supply of grease.

2. The bearing arrangement according to claim 1, wherein a waist of the
shaft adjoins the contact surface.

3. The bearing arrangement according to claim 2, wherein the waist is
arranged axially between a first section and a second section of the
contact surface.

4. The bearing arrangement according to claim 1, wherein the contact
surface is formed by at least one bar positioned on the shaft, contacting
the inner ring and integrated as a single piece with the shaft.

5. The bearing arrangement according to claim 1, wherein the first roller
bearing is designed as a fixed bearing.

6. The bearing arrangement according to claim 5, wherein the first roller
bearing has an outer ring which is inserted into a receiver section of
the first housing part, said receiver section being the inner boundary of
an end-face wall of the first housing part.

7. The bearing arrangement according to claim 6, wherein the receiver
section has a conical or polygonal shape, or is stepped.

8. The bearing arrangement according to claim 6, wherein the outer ring
is arrested in the receiver section of the first housing part.

9. The bearing arrangement according to claim 1, wherein the second
roller bearing is designed as a fixed bearing.

10. The bearing arrangement according to claim 1, wherein a shaft seal is
positioned on a side of the first roller bearing, which faces an internal
space of the housing of the electric motor.

[0002] The present disclosure describes a bearing arrangement in an
electric motor, having two roller bearings. At least one housing part of
the electric motor is made of plastic.

BACKGROUND

[0003] A bearing arrangement in the class is disclosed by way of example
in DE 10 2011 080 265 A1. This is a bearing arrangement which is used in
an electric motor of an electrical camshaft adjuster. The electric motor
has a housing which is composed of plastic and metal parts.

[0004] An electric motor which has housing parts--specifically bearing
shields--made of plastic is known from DE 10 2005 051 245 A1, by way of
example. A roller bearing used to mount the shaft of the electric motor
is held in each of two bearing shields--a front and a rear. The electric
motor can be a component of an electrical power tool.

[0005] A further electric motor having at least one housing part made of
plastic is known from EP 0 176 839 A1, for example. A bearing seat for
the purpose of mounting a rotor shaft is sprayed onto a motor housing in
this case. The bearing itself is designed as a plain bearing.

[0006] An electric motor having a bearing made partially as a roller
bearing and partially as a plain bearing is known from DE 195 24 953 A1,
by way of example. This electric motor also has a housing made of
plastic.

[0007] The use of an electric motor in a camshaft adjuster in an internal
combustion engine is known from DE 10 2004 062 037 A1, by way of example.
The electric motor in this case functions as an actuating drive of an
adjustment mechanism which is designed as a three-shaft transmission.

[0008] A further electric motor which functions as an actuating motor of a
camshaft adjuster is known by way of example from U.S. Pat. No. 8,220,426
B2. The rotor of this electric motor is mounted by means of two roller
bearings--specifically ball bearings.

[0009] In the case of roller bearings, the connections between the inner
ring and the shaft can be designed in various ways, and full-surface
contact between the inner ring of the bearing and the mounted shaft is
not necessarily the case. Bearings with only partial contact between the
bearing ring and the shaft are known, by way of example, from U.S. Pat.
No. 4,792,244 A and DD 93065 A1.

SUMMARY

[0010] The problem addressed by the present disclosure is that of
providing a bearing arrangement of an electric motor which is suitable
particularly for an electric camshaft adjuster, characterized by a
particularly good relationship between the complexity of manufacturing
thereof and the reproducibility of operating parameters, particularly the
loads placed on bearings, compared to the named prior art.

[0011] The bearing arrangement included in the present disclosure has two
roller bearings--for example, ball bearings--and serves the purpose of
mounting a shaft in an electric motor. The electric motor is, in an
example embodiment, an actuating motor of an electrical camshaft adjuster
of an internal combustion engine. The electric motor is designed, by way
of example, as a brushless, electronically commutated motor.

[0012] The housing of the electric motor, which accommodates both of the
roller bearings, is composed of a first, bowl-shaped housing part made of
metal, and a second housing part connected to the first and made of
plastic. In an example embodiment, the electric motor is designed as an
internal rotor motor. In an example embodiment, the electric motor is
constructed as an external rotor motor. In this latter case, the two
housing parts made of metal and/or plastic are rotating components of the
electric motor.

[0013] In each case, one of the roller bearings is designed as a fixed
bearing, and the other roller bearing is a floating bearing. A contact
surface which transmits force is formed between the inner ring of the
roller bearing, the same functioning as a fixed bearing, and the shaft.
According to the present disclosure, this contact surface is smaller than
an inner ring which is press-fitted onto a cylindrical shaft. The
force-transmitting contact surface is therefore smaller than the inner
running surface of the inner ring, and also smaller than the surface
section of the running surface of the shaft lying radially inside of this
running surface.

[0014] It is possible to achieve this reduction of the contact surface
compared to the conventional bearing arrangement by, firstly, the fact
that the shaft has a smaller diameter in a portion of the region in which
it is surrounded by the inner ring of the roller bearing, and therefore
does not contribute to the transmission of force between the shaft and
the inner ring in this sub-section. This sub-section of the shaft which
is deliberately not used as a contact surface is, for example, designed
in this case as a groove--also called a waist--in which the inner ring
projects into the same from both sides. The inner ring is therefore only
pressed onto the shaft in the region of its end faces. In contrast, in
the central region of the inner ring, in which the rolling elements roll,
no direct radial force is applied by the shaft to the inner ring.
Therefore, compared to solutions in the prior art, the expansion of the
inner ring resulting from the press-fitting onto the shaft is minimized.
This measure also minimizes any changes to the bearing geometry,
particularly the play thereof.

[0015] In an example embodiment, the reduction of the contact surface
between the shaft and the inner ring of the roller bearing compared to
the conventional bearing arrangements is realized by embossments on the
shaft--particularly bars which provide contact surfaces. In each case,
the total contact surface formed between the inner ring and the shaft is
advantageously not greater than 60%, particularly not greater than 50% of
the inner running surface of the inner ring. This means the surface which
would be available as a contact surface if the shaft were a constant
cylinder.

[0016] In an example embodiment, the roller bearing which functions as a
fixed bearing is held either in a housing part made of plastic or a
housing part made of metal. In the latter case, the outer ring of the
roller bearing included as a fixed bearing is pressed into a receiver
section of the housing part made of metal, by way of example. The
receiver section in this case constitutes the radially inner limit of an
end-face wall of the housing part made of metal, and can have a
cylindrical, slightly conical, or stepped shape. In an example embodiment
the substantially sleeve-like receiver section of the housing part made
of metal has a polygonal shape.

[0017] In each case, the geometry of the outer ring and of the receiver
section in the preferred design ensures that the outer ring is at most
minimally deformed when inserted into the housing. In this case, there
can even be a minimal play of the outer ring in the housing part. In an
example embodiment, as soon as the outer ring reaches the final position
during installation, it is fixed by caulking A small number of
embossments are needed in this case. This approach ensures that, on the
outer ring as well during the assembly of the bearing arrangement, no
forces are applied which would lead to a significant change in the
geometric parameters of the roller bearing--that is, to a change in the
play in the bearing.

[0018] In an example embodiment, the output of the shaft is arranged on
the end face of the housing part made of metal. The roller bearing
positioned on this end, for example, functioning as a fixed bearing, is
not sealed. A shaft seal is, for example, positioned on the side of this
roller bearing which faces the internal space of the housing. In contrast
to the roller bearing accommodated in the housing part made of metal, the
second roller bearing inserted in the housing part made of plastic--for
example by injection into the same--is a roller bearing which is sealed
on both ends thereof. As such, the first roller bearing is designed as an
open bearing which is lubricated by an operating medium, particularly
oil, and the second roller bearing is designed as a sealed bearing with a
lifetime supply of grease.

[0019] In an example embodiment, the housing of the electric motor as a
whole is connected to an adjacent component by means of fastening
elements attached to the housing part made of metal--for example by
bolting.

[0020] The advantage of the invention is particularly that a shaft, as
well as two roller bearings which mount the shaft, are fixed in the
housing of an electric motor in a compact and economical arrangement,
which can simultaneously be produced with tight manufacturing tolerances,
without additional installed components such as retaining rings. Each of
the roller bearings has a bearing play which does not change
significantly during the assembly of the bearing arrangement. At the same
time, the bearing arrangement reliably transmits all torques and forces
which arise.

BRIEF DESCRIPTION OF THE DRAWINGS

[0021] An example embodiment of invention bearing arrangement in an
electric motor is described below in further detail with reference to
drawings, wherein:

[0022] FIG. 1 shows an electric motor in an exploded view,

[0023] FIG. 2 shows a top view of the input side of the electric motor
according to FIG. 1,

[0024] FIG. 3 shows the electric motor in a cutaway view (along the line
"A-A" in FIG. 2),

[0025] FIG. 4 shows a detail "X" (in FIG. 3), specifically a first roller
bearing of the electric motor, and

[0026] FIG. 5 shows a detail "Y" (in FIG. 3), specifically of a second
roller bearing of the electric motor.

DETAILED DESCRIPTION

[0027] FIGS. 1 to 5 together show an electric motor, indicated by the
reference number 1--for example, an electronically commutated motor which
is part of a camshaft adjuster, which is not illustrated--of an internal
combustion engine. For the basic functionality of such a camshaft
adjuster, attention is hereby directed by way of example to the documents
DE 10 2004 062 037 A1 and U.S. Pat. No. 8,220,426 B2, noted above.

[0028] Electric motor 1 has housing 2 which is composed of two housing
parts 3, 4, particularly bowl-shaped housing part 3 made of metal, and
housing part 4 made of plastic. Shaft 7 is mounted in housing 2 by means
of roller bearing 5 and roller bearing 6. As is explained in further
detail below, roller bearing 5 is accommodated in this case in housing
part 3, and roller bearing 6 is accommodated in housing part 4. Both
roller bearings 5, 6 are designed as ball bearings.

[0029] Shaft 7 protrudes from housing 2 (more precisely: from the housing
part 3) by end face S1 thereof, and is connected at that location to
drive element 8 in a torque-proof manner. A regulating shaft or control
disk of a three-shaft transmission, which is not illustrated--by way of
example a strain wave gearing, a wobble plate mechanism, a cycloidal
drive or a planetary gearing--is adjusted by drive element 8, serving the
purpose of shifting the phase of a camshaft relative to a crankshaft of
an internal combustion engine. As long as the phase relation between the
camshaft and the crankshaft is not changed, drive element 8 and shaft 7
rotate at the rotation speed of the camshaft. The three-shaft
transmission actuated by electric motor 1 has a high gear ratio. A
rotation of drive element 8 by a certain angle relative to the camshaft
therefore leads to a change in the phase relation between the crankshaft
and the camshaft by a much smaller angle.

[0030] Electric motor 1 is sealed with respect to the internal space of
housing 2 by shaft seal ring 10. Shaft seal ring 10 in this case is
located in a space-saving manner on the side of roller bearing 5 which
faces the internal space of housing 2. Rotor 11 which is fixed to shaft 7
is also positioned in the internal space of housing 2, and carries
permanent magnets 12. Electric motor 1 is designed as a synchronous motor
excited by permanent magnets. Stator windings 13 which interact with
permanent magnets 12 are fixed to housing part 4 made of plastic.
Likewise, associated stator laminations 14 are accommodated in housing
part 4--for example, injected into the same. Housing part 4 has plugs 15
for the necessary electrical contact.

[0031] Circuit board 16 is inserted into housing part 4 toward end face S2
of electric motor 1 which faces away from metallic housing part 3, and is
closed with lid 17. Magnetic field sensors 18, which are used to detect
the angular position of shaft 7, as well as temperature sensor 19, are
positioned on circuit board 16. Electric motor 1 is attached to an
adjacent component (not pictured)--for example a cylinder head--by means
of housing flange 20 which is located on housing part 3, and seal 9 which
surrounds housing part 3 lies flush with housing flange 20 and the
cylinder head. Housing part 4, in contrast, is not directly mechanically
connected to an adjacent component.

[0032] Roller bearing 5, as a fixed bearing, and roller bearing 6, as a
floating bearing, are included inside the bearing arrangement which
comprises roller bearings 5, 6. The following also refers to FIG. 4 with
respect to the connection of roller bearing 5 to shaft 7 as well as the
installation of roller bearing 5 into housing part 3.

[0033] Roller bearing 5 has, as conventionally known, inner ring 21 and
outer ring 22, with rolling elements 23, for example balls, rolling
between the same. Balls 23 are guided by cage 24 Inner ring 21 is held on
shaft 7 by a press fit by contact surface 25 which is reduced compared to
conventional arrangements. To reduce contact surface 25, shaft 7 has
waist 26 which is positioned centrally between the end faces of inner
ring 21. Contact surface 25 is therefore solely composed of section 27
and section 28, wherein sections 27, 28--both with an annular shape--of
contact surface 25 together include at most half of the width of inner
ring 21, and exclude the central region of inner ring 21 in which is
found running surface 29 for rolling elements 23. In this way, radial
force is only transmitted between shaft 7 and inner ring 21 axially by
the regions which are distant from running surface 29--specifically via
sections 27, 28 of contact surface 25.

[0034] Outer ring 22 of roller bearing 5 is held in sleeve-like receiver
section 30 which connects as a part of housing part 3 to wall 31 of
housing part 3, said wall lying on end face 51 and substantially having
the shape of a disk. Facing the internal space of housing 2, receiver
section 30 has shoulder 32 oriented radially inward. Outer ring 22 lies
thereon and is therefore supported in the axial direction. Proceeding
from shoulder 32, receiver section 30 continues in the form of narrowed
sleeve section 33 in which shaft seal ring 10 is held.

[0035] Outer ring 22 is inserted into receiver section 30 with only a
minimal press fit, or even with some play. In order to prevent rotation
of outer ring 22, as well as displacement of the same outward in the
axial direction, arresting points 34 are formed at the transition between
wall 31 and receiver section 30, which fix outer ring 22 in housing part
3. Overall, the manner of the connection of ring 21 to shaft 7, and the
connection of outer ring 22 to housing part 3, keeps deformation of
roller bearing 5 caused by installation to a minimum, in such a manner
that the configuration reliably rules out significant changes in bearing
parameters, particularly radial bearing play, even at industrial mass
production scales.

[0036] FIG. 5 shows the arrangement of roller bearing 6, functioning as a
floating bearing, in housing 2 in detail. Similarly to roller bearing 5,
roller bearing 6 also has inner ring 35, outer ring 36, and balls as
rolling elements 37. In contrast to roller bearing 5, roller bearing 6 is
sealed on both ends thereof by seal 38, 39. No force fit occurs between
inner ring 35 and shaft 7, such that at least a minimal axial
displacement--particularly caused by temperature--between shaft 7 and
roller bearing 6 is possible at this position. Outer ring 36 is injected
into housing part 4 made of plastic. As such, bearing ring 36 is secured
in housing part 4 against both axial displacement and rotation.

[0037] It will be appreciated that various of the above-disclosed and
other features and functions, or alternatives thereof, may be desirably
combined into many other different systems or applications. Various
presently unforeseen or unanticipated alternatives, modifications,
variations, or improvements therein may be subsequently made by those
skilled in the art which are also intended to be encompassed by the
following claims.